Brushless direct current motor stator processing technology

Abstract

The invention relates to the technical field of motor stator production, and discloses a brushless direct current motor stator processing technology, which comprises the following steps of: assembling an insulating framework on a stator iron core, performing winding on the stator iron core, inserting a common lug plate, a U-phase wiring plate, a V-phase wiring plate and a W-phase wiring plate on the insulating framework, correspondingly welding a winding copper wire and the lug plate, and welding the winding copper wire and the lug plate. And a stator winding is arranged in the box body, and finally the U-phase wiring terminal is arranged in the U-phase wiring sheet, the V-phase wiring terminal is arranged in the V-phase wiring sheet, and the W-phase wiring terminal is arranged in the W-phase wiring sheet. The brushless direct current motor stator processing technology further optimizes procedures related to manual operation, has the advantages of being high in automation degree and high in continuous working capacity, and can effectively improve production quality and production efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of motor stator production, and particularly relates to a processing technology for a brushless DC motor stator. Background Art

[0002] With the mature development of technologies in the household appliance field and the rapid progress of power electronics technology, brushless DC motors are becoming more and more popular due to their advantages such as high efficiency and low noise. The current existing assembly process for brushless DC motor stators generally includes assembling a stator insulation skeleton, winding the stator core, inserting pins into the slots of the insulation skeleton, winding copper wires around the pins and cutting them close to the pins, immersing one end of the stator coil with pins in a paint stripper, then using a brush to brush off the paint on the part of the pins immersed in the paint stripper, welding the exposed copper wires and pins, testing for inter-turn short circuit, pouring insulating paint from the upper end of the winding, and finally welding a Hall plate on the pins. Since the processes of brushing off the paint with a brush and installing and welding the Hall plate are mainly carried out manually, the labor intensity of the staff is high, the work efficiency is low, it is not conducive to automated operation, and it will reduce the product production quality and production efficiency. Therefore, it is necessary to optimize the assembly process of the brushless DC motor stator. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the deficiencies existing in the prior art and provide a processing technology for a brushless DC motor stator with high automation degree, strong continuous working ability, and capable of effectively improving the production quality and production efficiency.

[0004] To solve the above technical problem, the present invention adopts the following technical solutions: A processing technology for a brushless DC motor stator includes the following steps: (S1) Assembling the stator insulation skeleton: fixedly installing the insulation skeleton on the stator core; (S2) Winding: clamping the stator core on a winding tooling for winding the winding; (S3) Inserting connection pieces: inserting a common connection piece, as well as U-phase, V-phase, and W-phase connection pieces on the insulation skeleton; (S4) Welding: welding the winding copper wires with the common connection piece, as well as the U-phase, V-phase, and W-phase connection pieces; (S5) Installing in a box: fixedly installing the stator core in a box; (S6) Install the UVW wiring group: Insert the U-phase wiring terminal with a V-groove into the U-phase wiring piece, wipe off the surface paint on the U-phase wiring piece through the V-groove, and weld the U-phase wiring terminal to the U-phase wiring piece; Insert the V-phase wiring terminal with a V-groove into the V-phase wiring piece, wipe off the surface paint on the V-phase wiring piece through the V-groove, and weld the V-phase wiring terminal to the V-phase wiring piece; Insert the W-phase wiring terminal with a V-groove into the W-phase wiring piece, wipe off the surface paint on the W-phase wiring piece through the V-groove, and weld the W-phase wiring terminal to the W-phase wiring piece.

[0005] As a further description of the above technical solution: In step (S2), a marking groove is provided on the stator core, the marking groove of the stator core is aligned with the rib of the winding tooling, the stator core is locked and fixed on the winding tooling, and the machine parameters of the winding tooling are adjusted according to the drawing requirements to perform winding.

[0006] In step (S3), the common wiring piece is inserted at one end of the diameter of the insulating skeleton, and the U-phase wiring piece, the V-phase wiring piece, and the W-phase wiring piece are inserted at the other end of the diameter of the insulating skeleton.

[0007] In step (S4), one ends of the U-phase winding, V-phase winding, and W-phase winding of the stator core are commonly connected to the common wiring piece, the other end of the U-phase winding of the stator core is connected to the U-phase wiring piece, the other end of the V-phase winding is connected to the V-phase wiring piece, and the other end of the W-phase winding is connected to the W-phase wiring piece.

[0008] In step (S4), after the connection of the common wiring piece, the U-phase wiring piece, the V-phase wiring piece, and the W-phase wiring piece is completed, impregnation is carried out, the insulating paint is poured into the winding, and the space air gap in the winding copper wire is filled with the insulating paint.

[0009] In step (S6), the U-phase wiring terminal is automatically inserted into the U-phase wiring piece through the insertion tooling, the V-phase wiring terminal is automatically inserted into the V-phase wiring piece, and the W-phase wiring terminal is automatically inserted into the W-phase wiring piece.

[0010] In step (S6), the U-phase wiring terminal, the V-phase wiring terminal, and the W-phase wiring terminal are covered by a junction box, and the junction box is fixedly installed on the box body.

[0011] Compared with the prior art, the advantages of the present invention are: The processing technology of the stator of the brushless DC motor of the present invention assembles an insulating skeleton on the stator core, winds the stator core with windings, inserts a common connection piece, a U-phase connection piece, a V-phase connection piece, and a W-phase connection piece on the insulating skeleton, welds the winding copper wires corresponding to the connection pieces, installs the stator winding into a box body, and finally installs a U-phase connection terminal into the U-phase connection piece, a V-phase connection terminal into the V-phase connection piece, and a W-phase connection terminal into the W-phase connection piece. Compared with the prior art, first, by inserting a common connection piece, a U-phase connection piece, a V-phase connection piece, and a W-phase connection piece on the insulating skeleton, the step of inserting pins into the notch of the insulating skeleton is replaced, thus eliminating the manual process of installing and welding the Hall plate on the pins; second, the connection terminals can be automatically inserted into the connection pieces through an insertion tooling. V-shaped grooves are provided on the U-phase connection terminal, the V-phase connection terminal, and the W-phase connection terminal. When inserting, the inner side of the V-shaped groove scratches the surface paint of the connection piece, realizing mechanical paint stripping, replacing the manual process of brushing off the paint with a brush. Furthermore, the processes involving manual operations are further optimized, having the advantages of high automation and strong continuous working ability, and can effectively improve the production quality and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a flowchart of the steps of the processing technology of the stator of the brushless DC motor of the present invention.

[0013] Figure 2 It is an assembly drawing of the insulating skeleton and the stator core in step S1.

[0014] Figure 3 It is an assembly drawing of the connection piece and the insulating skeleton in step S3.

[0015] Figure 4 It is an assembly drawing of the stator core and the box body in step S5.

[0016] Figure 5 It is an assembly drawing of the connection terminal and the connection piece in step S6.

[0017] Figure 6 For Figure 5 the detailed enlarged drawing of the assembly of the connection terminal and the connection piece in

[0018] Figure 7 It is a schematic structural diagram of the assembled brushless DC motor.

[0019] Legend: 100, V-shaped groove; 1, insulating skeleton; 2, stator core; 3, common connection piece; 4, U-phase connection piece; 5, V-phase connection piece; 6, W-phase connection piece; 7, box body; 8, U-phase connection terminal; 9, V-phase connection terminal; 10, W-phase connection terminal; 11, junction box. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0021] As Figures 1 to 7 shown, the processing technology of the stator of the brushless DC motor in this embodiment includes the following steps: (S1) Assemble the stator insulation skeleton: fixedly install the insulation skeleton 1 on the stator core 2; (S2) Wind the wire: clamp the stator core 2 on the winding tooling to wind the winding wire; (S3) Insert the connection piece: insert the common connection piece 3, the U-phase connection piece 4, the V-phase connection piece 5, and the W-phase connection piece 6 on the insulation skeleton 1; (S4) Weld: weld the winding copper wire to the common connection piece 3, the U-phase connection piece 4, the V-phase connection piece 5, and the W-phase connection piece 6; (S5) Install in the box: fixedly install the stator core 2 in the box 7; (S6) Install the UVW connection group: insert the U-phase connection terminal 8 with the V-shaped groove 100 into the U-phase connection piece 4, wipe off the surface paint on the U-phase connection piece 4 through the V-shaped groove 100, and weld the U-phase connection terminal 8 to the U-phase connection piece 4; insert the V-phase connection terminal 9 with the V-shaped groove 100 into the V-phase connection piece 5, wipe off the surface paint on the V-phase connection piece 5 through the V-shaped groove 100, and weld the V-phase connection terminal 9 to the V-phase connection piece 5; insert the W-phase connection terminal 10 with the V-shaped groove 100 into the W-phase connection piece 6, wipe off the surface paint on the W-phase connection piece 6 through the V-shaped groove 100, and weld the W-phase connection terminal 10 to the W-phase connection piece 6.

[0022] The processing technology of the stator of the brushless DC motor assembles the insulating skeleton 1 on the stator core 2, winds the stator core 2, inserts the common terminal piece 3, the U-phase terminal piece 4, the V-phase terminal piece 5 and the W-phase terminal piece 6 on the insulating skeleton 1, welds the winding copper wire corresponding to the terminal piece, installs the stator winding into the box body 7, and finally installs the U-phase terminal 8 into the U-phase terminal piece 4, the V-phase terminal 9 into the V-phase terminal piece 5, and the W-phase terminal 10 into the W-phase terminal piece 6. Compared with the prior art, first, by inserting the common terminal piece 3, the U-phase terminal piece 4, the V-phase terminal piece 5 and the W-phase terminal piece 6 on the insulating skeleton 1, the step of inserting the pin on the notch of the insulating skeleton is replaced, thus eliminating the manual process of installing and welding the Hall plate on the pin; second, the terminal can be automatically inserted into the terminal piece through the inserting tooling. V-shaped grooves 100 are provided on the U-phase terminal 8, the V-phase terminal 9 and the W-phase terminal 10. When inserting, the inner side of the V-shaped groove 100 scratches the surface paint of the terminal piece to realize mechanical paint stripping, replacing the manual process of brushing off the paint with a brush, thereby further optimizing the process involving manual operation, having the advantages of high automation and strong continuous working ability, and being able to effectively improve the production quality and production efficiency.

[0023] Specifically, in step (S2), a marking groove is provided on the stator core 2. The marking groove of the stator core 2 is aligned with the rib of the winding tooling, the stator core 2 is locked and fixed on the winding tooling, and the machine parameters of the winding tooling are adjusted according to the drawing requirements to wind the winding. Note that the stator core 2 must be fixed tightly, otherwise the copper wire is easily broken.

[0024] Specifically, in step (S3), the common terminal piece 3 is inserted at one end of the diameter of the insulating skeleton 1, and the U-phase terminal piece 4, the V-phase terminal piece 5 and the W-phase terminal piece 6 are inserted at the other end of the diameter of the insulating skeleton 1.

[0025] Specifically, in step (S4), one ends of the U-phase winding, the V-phase winding and the W-phase winding of the stator core 2 are commonly connected to the common terminal piece 3, the other end of the U-phase winding of the stator core 2 is connected to the U-phase terminal piece 4, the other end of the V-phase winding is connected to the V-phase terminal piece 5, and the other end of the W-phase winding is connected to the W-phase terminal piece 6.

[0026] Specifically, in step (S4), after the common connection piece 3, the U-phase connection piece 4, the V-phase connection piece 5, and the W-phase connection piece 6 are wired, impregnation varnish is poured into the winding to fill the space air gap in the winding copper wire with the insulating varnish. The impregnated stator winding is then placed in an oven and baked at 130 °C for about two hours. The purpose of impregnation: to remove moisture in the insulating material and fill the space air gap in the copper wire with the insulating varnish, which can not only improve the insulation strength and moisture-proof performance of the winding, but also improve the heat resistance and heat dissipation of the winding, and can also improve the mechanical properties, chemical stability, thermal conductivity, heat dissipation effect and aging delay of the winding insulation.

[0027] Specifically, in step (S6), the U-phase connection terminal 8 is automatically inserted into the U-phase connection piece 4, the V-phase connection terminal 9 is automatically inserted into the V-phase connection piece 5, and the W-phase connection terminal 10 is automatically inserted into the W-phase connection piece 6 through a plugging tooling, with a high degree of automation and further improving production efficiency.

[0028] Specifically, in step (S6), the U-phase connection terminal 8, the V-phase connection terminal 9, and the W-phase connection terminal 10 are covered by a junction box 11, and the junction box 11 is fixedly installed on the box body 7, which can prevent external force impact from damaging the connection terminals and is beneficial to extending the service life.

[0029] The above are only the preferred embodiments of the present invention, and the protection scope of the present invention is not limited to the above embodiments. For those skilled in the art of this technology, the improvements and transformations obtained without departing from the technical concept of the present invention should also be regarded as the protection scope of the present invention.

Claims

1. A brushless DC motor stator processing technology, characterized in that: The following steps are involved: (S1) Assembling the stator insulation frame: fixing the insulation frame (1) on the stator core (2); (S2) Winding: Clamping the stator core (2) on a winding tool to perform winding; (S3) Inserting the lugs: inserting the common lug (3), the U-phase lug (4), the V-phase lug (5) and the W-phase lug (6) on the insulating frame (1); (S4) Welding: welding the winding copper wire to the common lug (3), the U-phase lug (4), the V-phase lug (5) and the W-phase lug (6); (S5) Installing into a housing: fixing the stator core (2) into the housing (7); (S6) Inserting the UVW wiring group: inserting the U-phase wiring terminal (8) having the V-shaped groove (100) into the U-phase wiring lug (4), erasing the surface paint on the U-phase wiring lug (4) through the V-shaped groove (100), and welding the U-phase wiring terminal (8) to the U-phase wiring lug (4); inserting the V-phase wiring terminal (9) having the V-shaped groove (100) into the V-phase wiring lug (5), erasing the surface paint on the V-phase wiring lug (5) through the V-shaped groove (100), and welding the V-phase wiring terminal (9) to the V-phase wiring lug (5); inserting the W-phase wiring terminal (10) having the V-shaped groove (100) into the W-phase wiring lug (6), erasing the surface paint on the W-phase wiring lug (6) through the V-shaped groove (100), and welding the W-phase wiring terminal (10) to the W-phase wiring lug (6).

2. The brushless DC motor stator processing technology according to claim 1, characterized in that: In step (S2), the stator core (2) is provided with a marking groove, the marking groove of the stator core (2) is aligned with the rib of the winding tool, the stator core (2) is locked and fixed on the winding tool, and the machine parameters of the winding tool are adjusted according to the requirements of the drawing to carry out winding.

3. The brushless DC motor stator processing technology according to claim 2, characterized in that: In step (S3), the common wiring lug (3) is plugged into one end of the diameter of the insulating frame (1), and the U-phase wiring lug (4), the V-phase wiring lug (5) and the W-phase wiring lug (6) are plugged into the other end of the diameter of the insulating frame (1).

4. The brushless DC motor stator processing technology according to claim 3, characterized in that: In step (S4), one end of the U-phase winding, the V-phase winding and the W-phase winding of the stator core (2) are connected to the common connecting piece (3), the other end of the U-phase winding of the stator core (2) is connected to the U-phase connecting piece (4), the other end of the V-phase winding is connected to the V-phase connecting piece (5), and the other end of the W-phase winding is connected to the W-phase connecting piece (6).

5. The brushless DC motor stator processing technology according to claim 4, characterized in that: In step (S4), after the common terminal lug (3), the U-phase terminal lug (4), the V-phase terminal lug (5) and the W-phase terminal lug (6) are connected, they are dipped in varnish, and the insulating varnish is poured into the winding to fill the air gap in the copper wire of the winding with the insulating varnish.

6. The brushless DC motor stator processing technology according to claim 5, characterized in that: In step (S6), the U-phase terminal (8) is automatically inserted into the U-phase lug (4) by means of a plug-in tool, the V-phase terminal (9) is automatically inserted into the V-phase lug (5), and the W-phase terminal (10) is automatically inserted into the W-phase lug (6).

7. The brushless DC motor stator processing technology according to claim 6, characterized in that: In step (S6), the U-phase terminal (8), the V-phase terminal (9) and the W-phase terminal (10) are covered by a terminal box (11), and the terminal box (11) is fixedly mounted on the box body (7).

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